SERVICE MANUAL. Inlet. Cold water. MODEL # ORDER # HDS 4.0/20 E Ec / EEC C HDS 4.0/30 E Ec / EEC C

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2 CONTENTS Exploded View 4-5 Exploded View Parts List 6-7 Cabinet Exploded View 8-9 Cabinet Parts List 10 Hose and Spray Gun Assembly 11 Specifications Unloader Adjustment Procedure 13 VBR & VB8 Unloader Valve Exploded View & Parts List KM Series Exploded View & Parts List Troubleshooting Wiring Diagrams Model Number Serial Number Date of Purchase The model and serial numbers will be found on a decal attached to the pressure washer. You should record both serial number and date of purchase and keep in a safe place for future reference. 2

4 OPERATOR S MANUAL PRESSURE WASHER 25 Exploded View - Left Side Time Delay Option Reversed View of Electrical Panel Components , Time Delay Option

5 Exploded View - Right Side PRESSURE WASHER OPERATOR S MANUAL

6 OPERATOR S MANUAL PRESSURE WASHER 6 ITEM PART NO. DESCRIPTION QTY Unloader, PA 8GPM@3650 PSI, VB8 W/Switch Unloader, AL (VRT607) (Time Delay Option) 1 2 Pump, See Specification Pages 3 Motor, See Specification Pages 4 Overload, See Specification Pages 5 Transformer, See Specification Pages 6 Fuse, See Specification Pages 7 Fuse, See Specification Page Contactor, See Specification Pages Hose, 1/2" Push On 18" Din Rail, 35mm 4" Exploded View Parts List (Time Delay Option) 6" Box, Plastic, 10" x 8" x 6" w/lid Bracket, Support for Elec Box Strain Relief, 3/4" LQ Tite Locknut, 3/4" Strain Relief, Strt, LQ Tite, Med Locknut, 1/2" Conduit Hose, 3/8" x 22", 2 Wire, Pressure Loop Pump Protector, 1/2, Timer, Multi-Function (Time Delay Option) Elbow, 1/2" JIC, 3/8", Nut, 3/8" ESNA Washer, 3/8", SAE, Flat Nipple, 1/2" Hex Tee, 1/2" Female, Pipe Nipple, 1/2" JIC x 1/2" MPT Pipe Elbow, 1/2" JIC x 1/2", Elbow, 1/2" JIC x 3/8" Steel Elbow, 1/2" x JIC x 3/8", Brass Washer, 3/8 Flat Cover, Kärcher Base, Kärcher Switch, Rocker, Carling w/green Lens Switch, Rocker, Red Face (Time Delay Only) Pad, Soft Rubber, 50 Duro Grommet, Rubber, Nozzle Holder Swivel, 1/2" MP x 3/4" GHF w/strainer Connector, 1/2" Anchor 1 ITEM PART NO. DESCRIPTION QTY Connector, 3/8" Anchor Bolt, Pump Mounting Elbow, 1/2" JIC x 3/8" 90 MPT Nozzle, SAQCMEG 0004 Red (HDS 4.0/30) Nozzle, SAQCMEG 0006 Red (HDS 4.0/20) Nozzle, SAQCMEG 1504 Yellow (HDS 4.0/30) Nozzle, SAQCMEG 1506 Yellow (HDS 4.0/20) Nozzle, SAQCMEG 2504 Green (HDS 4.0/30) Nozzle, SAQCMEG 2506 Green (HDS 4.0/20) Nozzle, SAQCMEG 4004, White (HDS 4.0/30) Nozzle, SAQCMEG 4006, White (HDS 4.0/20) Label Karcher Control Panel CT Label Karcher Stripe 17" 2 44 Bushing, See Specification Pages 45 Bushing, See Specification Pages 46 Pulley, See Specification Pages 47 Pulley, See Specification Pages 48 Belt, See Specification Pages Swivel, 1/2" JIC Fem, 3/8" Male Screw, 1/4"x1/2" BH SOC ES Washer, 3/8" x 1" Steel Hour Meter, 115 VAC Bolt, 3/8" x 1", NC HH Label, Warning, Exposed Pulley Label, Cold Water Outlet Service Cord 12/4 10 ft Label, GFCI Strain Relief 1" Service Cord 12/4 40" Strain Relief, Strt, LQ Tite 3234 Large Locknut, 3/4" Label, Intended For Indoor Use Hose, 1/2" Push-on 12" Nut, 3/8" ESNA NC Elbow, 3/8" Street Switch, Pressure (Time Delay Option) Strain Relief, 1/2" Locknut, 1/2" 1

7 ITEM PART NO. DESCRIPTION QTY Cover, Access Hole Label, Caution Label, Cold Water Inlet Washer, 5/16" Flat Bolt, 1/2" x 8" NC HH Washer, 1/2" Flat Slider, Pump Nut, 5/16" ESNA Elbow, 1/2" JIC x 3/8" Female, 90 DGR Bushing, 1/2" x 3/8" Steel Clear Lexan Detergent label Bumper Pad Weather Stripping 7 ft Nut, 1/4" Square Swivel, 1/2" JIC Fem. Push-On Cord, 16-4 Service 30" Nut, 10/32" Keps Bolt, 3/8" x 1-1/2" NC HH Screw, 10/32" x 1/2" Black Screw, 10/32" x 1-1/4" Nut, 1/4" ESNA NC Cage Nut, 10/32" x 16 Gauge Cage Nut, 1/4" x 12 Gauge Washer, 3/8" x 1-1/2" Fender Label, Ground Standoff, Electrical Box Strain Relief, 3/4" Timer, Solid State, 120V 5-60 Min. Adjust Plug, 3/8" Gas Tap (Time Delay Option) Elbow, 1/2 JIC x 1/2 MPT (Time Delay) Elbow, 1/2 JIC x 3/8 Fem (Time Delay) Label, Shark, Die Cut 2 Exploded View Parts List PRESSURE WASHER OPERATOR S MANUAL Not Shown 7

8 Part No. OPERATOR S MANUAL PRESSURE WASHER Cabinet Exploded View - Left Side To Pressure Washer WARNING: TANK FILL ELBOW DO NOT PLUG VENT HOLE

9 Cabinet Exploded View - Right Side Coil Assembly PRESSURE WASHER OPERATOR S MANUAL L1 L2 L

10 OPERATOR S MANUAL PRESSURE WASHER ITEM PART NO. DESCRIPTION QTY Elbow, 1/2" JIC x 3/8" MPT Lid, Top Cover Outer Wrap, Fill Side Outer Wrap, Power Side Label, Heating Unit Power Light, Green 125V Switch, Rocker Carling w/green Lens Timer, 7 Day Pin, 120V, 20A PB873MKZ Elbow, 1/4" Street, 90 Galv Switch, Limit w/clamp Tank Assembly Gasket, 6000W Heater, 2500 Series Heater, 4500W 480V # Plug, 1.5" Pipe, Black Elbow, 1-1/2" Female, Black Strain Relief, Large Locknut, 3/4" Tank Assembly Lid Bracket, Coil Pad, 1/4" Rubber, Coil Hose, 3/8" x 1/2" Push-on Bracket, Coil Spacer Tube Fitting, Parker 8MSC6N-316 1/2" SS A-Lok Elbow, 3/8" Street Connector, 3/8" Anchor Terminal, Grounding Lug, 1/0-6 Copper Wire Block, Power Distr, 3 Pol, GO Block, Terminal, 4 Pole Contactor, 120V Tank Base Assembly Bolt, 1/2" x 3" NC, SS Holder, Fuse Block, Buss R CR Fuse, Buss FRS-R-50, 600V 50 Amp Transformer, 208/230/460V- 24/115V,.050KVA 1 Cabinet Parts List ITEM PART NO. DESCRIPTION QTY Switch TH HI 84 C NC 1/2 x 1/2 SP Electrical Panel Label, Disconnect Power Supply Plate, Back Cover Plate, Electrical Access Label, Warning Coil, 1/2" O.D. SS Tubing Nut, Cage 1/4" x 16 Ga Screw, 1/4" x 1/2" HH NC Whiz Lock Insulation, 1" x 24" x 48" Fiberglass, Foil One Side Gasket, Neop 8 ft Screw, 8/32" x 1-1/2", SS Phil PH Screw, 5/16" x 3/4" Whiz Nut, Whiz Loc, 5/16 Flange Bolt, 5/16" x 2" NC HH Clamp, Tie Wrap Adhesive Screw, 1/4" x 1/2" BH SOC CS Screw, #8 x 1" Phil Pan Sheet Metal Screw, #6 x 3/8" Phil Pan Sheet Metal Label, Incoming Line Hose, 1/2" Push-on 1 ft Label, Ground Symbol Bushing, Snap 5/ Nipple, 1/2" Hex Steel Weatherstrip, 1/8" x 1/2" 10 ft Screw, 10/32" x 3/4" BHSOC Nut, 10/32" Keps Fuse, Paper Bass 8/10 250V Fuse, Class R1/2 Amp Screw, 10/32" x 1/2" BH SOC Label, Fill Elbow Label, Hot Water Outlet Label, Class RD5, 50 Amp Label, XFMR Primary/Secondary Fuses Screw, 1/4" x 1", BH SOC CS Nut, 1/4" ESNA, NC Grommmet, 1-5/16" Rubber Detergent Injector Assy, Non-Adj. #3 1 10

11 1 Hose & Spray Gun Assembly and parts list 2 High Pressure Nozzle PRESSURE WASHER OPERATOR S MANUAL Hose & Spray Gun Assembly and parts list ITEM PART NO. DESCRIPTION QTY Coupler, 1/4" Male Quick Coupler O-Ring, Small Nozzle Only, 1/8", Soap Wand, SS, VP, AL344 w/coupler & Soap Nozzle 1 4 See Nozzles, Page Hose, 3/8" x 50', 1 Wire, Tuff-Flex 1 ITEM PART NO. DESCRIPTION QTY Spray Gun Detergent Injector, Non-Adjust 3-5 GPM Strainer, 1/4" Hose Barb Tube, 1/4" x 1/2" Clear Vinyl 6 ft Clamp, Hose, UNI Not Shown 11

12 PRESSURE WASHER Specifications Model# HP Motor Pump Pump Pulley Specifications Pump Pulley Description Motor Pulley Motor Pulley Description Pump Bushing Description hp AK74H AK56H 24 mm hp BK80H BK52H 24 mm 12

13 Model# Pump Bushings Motor Bushing Specifications Motor Bushing# Belt Belt# Contactor Overload Fuse Primary Fuse Secondary Transformer H x 1-1/8" AX (2) (1) H x 1-3/8" BX (2) (1) PRESSURE WASHER Specifications Remove lock nut (Item 7). Remove adjustment knob (Item 8). Unloader Adjustment Procedures Loosen the two (2) nuts (Items 25), move them upward on stem (Item 14) until you see 4 or more threads below the nut. Re-attach adjusting knob (Item 8). Start machine. Open the trigger of the spray gun. Increase pressure by turning adjustment knob (Item 8) clockwise until pressure is at the desired operating pressure. Remove the adjustment knob (Item 8), tighten the lower nut (item 25) tightly against the upper nut (Item 25). Re-attach adjustment knob (Item 8) and screw down until contact is made with the nuts (Item 25). Screw down lock nut (Item 7) onto the stem (Item 14) until the threads cut into the nylon insert of the lock nut (Item 7). *If adjustment knob (Item 8) DOES NOT make contact with upper nut (Item 25), remove adjusting knob (Item 8), re-adjust (raise) nuts (Items 25) on stem (Item 14) and re-attach adjustment knob (Item 8), then repeat step #6. **If adjustment knob (Item 8) DOES make contact with upper nut, release the trigger of the spray gun and watch the pressure gauge for the pressure increase ( spike ). This spike SHOULD NOT exceed 500 psi above the operating pressure. If spike pressure exceeds the 500 psi limit, remove the adjusting knob (Item 8) and re-adjust (lower) the nuts (Items 25) on the stem (Item 14). Re-attach the adjusting knob (Item 8), then repeat step #6. 13

14 OPERATOR S MANUAL PRESSURE WASHER PSI Red Knob PSI Yellow Knob VBR UNLOADER VALVE EXPLODED VIEW Kit "A" Outlet Kit Kit "B" Inlet Kit Kit "C" Stem Seal Kit Kit "D" Stem Kit VBR UNLOADER VALVE EXPLODED VIEW PARTS LIST ITEM# Part # description Kit qty Nut, Locking Handle, Red Handle, Yellow 1 3 Space, Anti-friction D 1 4 Plate D 1 5 Spring D Stem Nut D O-Ring, Nut C 1 8 Spacer, Red 1 Spacer, Yellow 1 Spacer, Green 1 Spacer, Blue 1 9 Stem D O-Ring, Back up C O-Ring, Stem C Plug, 3/ Washer, 3/8 2 ITEM# Part # description Kit qty Body O-Ring, Seat B 1 16 Seat B 1 17 Ball, 7/16 B 1 18 Spring B 1 19 O-Ring, Connector B 2 20 Connector, Inlet 1 21 Pin C O-Ring, Backup 106 C 1 23 O-Ring, Stem C Washer, 1/ Plug, 1/ Poppet Spring A Connector, Outlet A 1 14

15 VB8 Unloader Valve exploded view & parts list PSI PRESSURE WASHER OPERATOR S MANUAL ITEM PART NO. DESCRIPTION QTY /8 Bsp F Outlet Fitting * O-ring 1.78 x mm 2 3 Spring 1 4 Check Valve * O-ring 3 x 6 mm 1 6 VB8 Brass Body 1 7 O-Ring 2,.62 x 7.6 mm 1 8 Piston 1 9 O-ring 1 x 4 mm * O-ring 1.78 x 15.6 mm 1 11 M 6 Nut 1 12 VB8/9 Seat+Shutter 1 13 Back Ring 11.4 x 15.9 mm 2 14 O-ring 2.62 x mm 1 15 Spring Guide 1 16 O-ring 2.62 x 5.23 mm 1 17 Piston Housing 1 18 M 4 x 4 mm Dowel 1 19 M 22 Nut 1 20 Washer 9 x 15 mm x 33 mm Spring 1 ITEM PART NO. DESCRIPTION QTY 22 Upper Frame /4" Ball 1 24 Brass Cap 1 25 Sst Clip 1 26 Plastic Housing 1 27 El.cable + micro Switch 1 28 O-ring 2.62 x mm x 12 mm Screw 2 30 Cover 1 31 O-ring 2.62 x 6.02 mm 1 32 Black nut-40 bar 1 33 O-ring 1.78 x 3.68 mm 1 34 Sst washer 4 x 8 mm 1 35 Spring 1 36 PR 5 pin 1 37 Plastic handle ( ) 1 38 Washer D. 30 mm ( ) 1 39 M 30 nut ( ) PR 5 pl.housing kit 1 15

16 OPERATOR S MANUAL PRESSURE WASHER KM4035R.2 KM.2 Pump exploded view KM.2 Pump exploded view parts list TORQUE SPECS Item # Ft.-lbs ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY Crankcase Hexagonal Screw Plunger Guide Closed Bearing Housing 1 3* See Kits Plunger Oil Seal O-Ring Ø1.78 x * See Kits O-Ring Ø1.78 x Tapered Roller Bearing 2 5* See Kits Pressure Ring Crankshaft (5030, 3540) 1 6* See Kits U-Seal Crankshaft (4030, 4035, 6035) 1 7* See Kits Intermediate Ring Crankshaft Key 1 8* See Kits Back-up Ring Oil Dip Stick 1 9* See Kits U-Seal Crankshaft Seal 1 10* See Kits Support Ring Shim Manifold Head Bearing Housing 1 14* See Kits O-Ring Ø2.62 x * See Kits Plunger Bolt 3 15* See Kits Valve Assembly 6 37* See Kits Copper Spacer 3 16* See Kits O-Ring Ø2.62 x * See Kits O-Ring Ø1.78 x Valve Plug 6 39* See Kits Teflon Ring Manifold Stud Bolt 8 40* See Kits Plunger (4035, 6035) Washer 16 See Kits Plunger (4030, 5030) Copper Washer 3/8 1 See Kits Plunger (3540) Brass Plug 3/8 1 41* See Kits Copper Spacer 3

17 KM.2 Pump exploded view parts list (cont) ITEM PART NO. DESCRIPTION QTY Plunger Rod Connecting Rod Snap Ring Connecting Rod Pin Spring Washer Connecting Rod Screw O-Ring, Ø2.62 x Crankcase Cover O-Ring, Ø1.78 x Sight Glass 3/ Cover Screw 5 * Available in kit (See below) PRESSURE WASHER OPERATOR S MANUAL Repair kit no KIT DESCRIPTION item numbers included No. of cylinders kit will service Plunger Seal mm 4, 6, 8, 9, 10 Plunger Seal mm 4, 6, 8, 9, 10 Plunger Seal mm 4, 6, 8, 9, 10 Complete Seal Packing mm 4, 5, 6, 7, 8, 9, 10 Complete Seal Packing mm 4, 5, 6, 7, 8, 9, 10 Complete Seal Packing mm 4, 5, 6, 7, 8, 9, Repair kit no KIT DESCRIPTION item numbers included No. of cylinders kit will service Plunger mm 36, 37, 38, 39, 40, 41 Plunger mm 36, 37, 38, 39, 40, 41 Plunger mm 36, 37, 38, 39, 40, 41 Complete Valve Plunger Oil Seals 14, 15,

18 PRESSURE WASHER Troubleshooting Guide Troubleshooting PROBLEM POSSIBLE CAUSE SOLUTION LOW OPERATING PRESSURE FLUCTUATING PRESSURE PRESSURE LOW AFTER PERIOD OF NORMAL USE PUMP NOISY Faulty pressure gauge Insufficient water supply Old, worn or incorrect spray nozzle Plumbing or hose leak Faulty or misadjusted unloader valve (where applicable) Worn packing in pump Fouled or dirty inlet or discharge valves in pump Worn inlet or discharge valves Leaking pressure control valve (where applicable) Valves worn Blockage in valve Pump sucking air Worn piston packing Nozzle worn Inlet or discharge valves blocked or worn Unloader valve seat worn Air in suction line Broken or weak inlet or discharge valve springs Foreign matter in valves Install new gauge. Use larger garden hose; clean filter washer at water inlet. Match nozzle number to machine and/or replace with new nozzle. Check plumbing system for leaks. Retape leaks with teflon tape. Adjust unloader for proper pressure. Install repair kit when needed. Install new packing kit. Clean inlet and discharge valves. Replace with valve kit. Rebuild or replace as needed. Check and replace if necessary. Check and clean out if necessary. Check water supply and suction line for air seepage at joints. Check and replace if necessary. Check and replace if necessary. Check and clean or replace if necessary. Check and replace if necessary. Check water supply connections on suction line. Check and replace if necessary. Check and clean if necessary. PRESENCE OF WATER IN PUMP OIL Worn bearings Water sprayed at machine High humidity in air Piston packing worn. Oil seal worn Check and replace if necessary. Change oil. Direct spray away from machine. Check and change oil twice as often. Check and replace if necessary. 18

19 Troubleshooting PROBLEM POSSIBLE CAUSE SOLUTION OIL SQUIRTS OUT OF OIL CAP ON PUMP WATER DRIPPING FROM UNDER PUMP Pump overfilled with oil Piston packing worn O-Ring plunger retainer worn Cracked piston Maintain oil level at red dot on sight glass at rear of pump or at top of notch on dipstick (where applicable). Check and replace if necessary. Check and replace if necessary. Check and replace if necessary. OIL DRIPPING Oil seal worn Check and replace if necessary. EXCESSIVE VIBRATION IN DELIVERY LINE Irregular functioning of the valves Check and replace if necessary. SYSTEM WILL NOT START Power, water, auto switch not on Check and turn on. Motor overload tripped Control fuse blown (2 or 3 amp) Pressure switch faulty Timer faulty Check and reset. Check and replace. Check, clean or replace. Check and replace. SYSTEM WILL NOT STOP Water leak in discharge line Repair water leak. SYSTEM STOPS AFTER APPROXIMATELY 10 SECONDS AND THEN RESTARTS Pressure switch faulty Timer resistor faulty Faulty pressure switch Leak in system Disconnect at timer. If unit stops, replace pressure switch. Replace timer. Check and replace. Fix leak. WATER IS NOT HOT Tank water low Check for leaks and fill. MOTOR HUMS BUT DOES NOT TURN PUMP RUNNING NORMALLY BUT LOW WATER PRESURE Temperature or level controls faulty Electric motor single phasing Air leak in inlet Faulty pressure unloader Check and replace. Check for blown fuse or loose power line connections. Check water supply and possibility of air entering water connections. Bypass pressure unloader by wiring spray gun open. If good PSI, turn machine off and replace regulator. DO NOT RELEASE SPRAY GUN WHILE BYPASSING UNLOADER. PRESSURE WASHER Troubleshooting Guide 19

20 PRESSURE WASHER Troubleshooting Guide Troubleshooting PROBLEM POSSIBLE CAUSE SOLUTION WATER ESCAPING FROM FILL PIPE ON HEAT EXCHANGER UNLOADER DOES NOT GO INTO BYPASS OR WILL CYCLE ITSELF SPIKES TOO HIGH SYSTEM WON T COME UP TO PRESSURE Cold water added to heat exchanger Ruptured coil or leaking Spray gun or hose is leaking to atmosphere Check plunger either did not move or did not seal Actuator o-ring failure Slow moving actuator; this may be caused by bad o-rings either on the plunger or inside the actuator fitting. Spring tension Hose length Water is leaking between ball and seat O-Rings on actuator plunger are bad Locknut may be improperly set Tip/GPM combination is incorrect Tip worn- the GPM may be greater than expected with a worn tip Bad gauge - the pressure may be higher than the gauge shows Will stop once at operating temperature. Check, repair or replace fittings. Check and repair all leaks. Remove discharge port. Clean and inspect the check plunger. Replace the o-ring if needed. Remove actuator plunger assembly and inspect o-ring and back-up rings. Replace if necessary. Remove the actuator assembly to inspect the o-ring and back-up rings. The actuator assembly will have to be disassembled to inspect and/or replace the o-rings in the actuator fitting. Adjustment should stop when pressure is no longer affected by further compression of the spring. Hose length can affect the amount of spike pressure. Long lengths of hose may cause high spike pressures. Disassemble inlet fitting and check for contaminates or worn parts. Clean or replace as needed. Remove actuator assembly and inspect o-ring and back-up rings. Replace if necessary. Readjust locknut. NOTE: The locknut is inside the spring on models that have the stem exposed above the spring. Check actual GPM on unrestricted pump and size tip accordingly. Replace tip. Replace gauge. 20

21 WIRING DIAGRAM - WITH AUTO START/STOP PRESSURE WASHER OPERATOR S MANUAL 21

22 OPERATOR S MANUAL PRESSURE WASHER WIRING DIAGRAM - WITH TIME DELAY SHUTDOWN OPTION 22

24 Form # Revised 6/09 Printed in U.S.A. or Mexico

SERVICE MANUAL

SERVICE MANUAL LISTED MODEL # ORDER # BDE-505009B 1.107-085.0 BDE-505009C 1.107-086.0 MPE5-50024B 1.106-001.0 MPE5-50024C 1.106-002.0 HD 5.0/50 Eb CAGE 1.107-084.0 HD 5.5/50 Ec CAGE 1.107-087.0 BRE-505007B